Hard hat suspension

ABSTRACT

A hard hat suspension is provided for use in a hard hat for protecting a wearer&#39;s head. The hard hat comprises a rigid outer shell. The suspension comprises a central portion for resting on the wearer&#39;s head, and a plurality of resilient impact absorbing corrugated strap members depending from the central portion. At least some, or all, of the strap members comprise a corrugated segment and terminate in an uncorrugated attachment end that is configured for attachment to an inner surface of the rigid outer shell. The suspension may be of unitary construction or may be formed of separate strap members.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of priority of U.S. Provisional Patent Application No. 61/603,714 filed Feb. 27, 2012, which is incorporated herein by reference in its entirety.

FIELD

The present disclosure relates generally to protective equipment. More particularly, the present disclosure relates to a suspension for a hard hat.

BACKGROUND

Hard hats are commonly used as safety devices on construction sites and in other locations where it is desirable to protect a wearer's head from damage caused by impact. A hard hat includes a moulded hard plastic hat shell, which is inexpensive to produce.

Most hard hats include a nylon web suspension for absorbing or softening/spreading forces transmitted through the hard hat shell to the wearer's head. The suspension typically includes a set of two flat crossing nylon straps, and optionally a small square padding at the intersection thereof. The suspension can also include a circumferential head strap, sometimes including brow and/or neck padding.

It is desirable to provide a suspension that provides an alternative approach to impact absorption, in a way that still addresses relevant safety issues.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present disclosure will now be described, by way of example only, with reference to the attached Figures.

FIG. 1 is a plan view of an integrally formed suspension for a hard hat, according to one embodiment of the present disclosure.

FIG. 2 is a plan view of an integrally formed suspension for a hard hat, according to another embodiment of the present disclosure.

FIG. 3 is a plan view of an integrally formed suspension for a hard hat, according to a further embodiment of the present disclosure.

FIG. 4 is a perspective view of a suspension strap for a hard hat according to one embodiment of the present disclosure.

FIG. 5 depicts perspective, plan and elevated views of the strap of FIG. 4.

FIG. 6 is a perspective view of a suspension strap according to another embodiment of the present disclosure.

FIG. 7 depicts perspective, plan and elevated views of the strap of FIG. 6.

FIG. 8 is a perspective view of a suspension strap according to a further embodiment of the present disclosure.

FIG. 9 depicts perspective, plan and elevated views of the strap of FIG. 8.

DETAILED DESCRIPTION

A hard hat suspension is provided for a hard hat that protects a wearer's head. The hard hat comprises a rigid outer shell. The suspension comprises a central portion for resting on the wearer's head, and a plurality of resilient impact absorbing corrugated strap members depending from the central portion. At least some, or all, of the strap members comprise a corrugated segment and terminate in an uncorrugated attachment end that is configured for attachment to an inner surface of the rigid outer shell. The suspension may be of unitary construction or may be formed of separate strap members.

It is an object of the present disclosure to obviate or mitigate at least one disadvantage of previous approaches. Any advantages stated herein may pertain to certain aspects or embodiments, and not necessarily to all aspects or embodiments.

In one embodiment, the present disclosure provides a hard hat suspension for use in a hard hat for protecting a wearer's head. The suspension includes a central portion for resting on the wearer's head, and a plurality of resilient impact absorbing corrugated strap members depending from the central portion. At least some of the plurality of strap members include a corrugated segment and terminate in an uncorrugated attachment end that is configured for attachment to the hard hat.

In some embodiments, each of the plurality of strap members comprises the corrugated segment and terminates in the uncorrugated attachment end. The plurality of strap members can be distributed substantially equidistantly about the perimeter of the central portion of the suspension. The plurality of strap members can comprise four strap members positioned in a substantially X-shaped configuration. The strap members can be positioned to define a first pair of opposing obtuse angles within the X-shape, and a second pair of opposing acute angles within the X-shape. In such a configuration, the four strap members can comprise two pairs of diagonally opposing strap members, each diagonally opposing strap member being substantially parallel to the other strap member in its pair.

In some embodiments, the central portion can be elongated in one dimension to position the strap members for attachment to the rigid outer shell with minimal stress. The uncorrugated attachment end of each strap member can be angled with respect to the corrugated segment of the strap member. The diagonally opposing strap members can be offset from one another.

In some embodiments, the corrugated segment of at least one of the strap members comprises two rows of corrugations. The two rows of corrugations can define an aperture therebetween. The corrugated segment of each of the strap members can comprise ridges which project towards the inner surface of the rigid outer shell. The ridges can be separated by flat spacer portions configured to comfortably abut the wearer's head.

In some embodiments, the central portion defines a central aperture for weakening the central portion and improving shock absorption. The central aperture can be ovoid, or any other suitable shape.

In some embodiments, the corrugated segment of the strap members comprises at least three ridges. In other embodiments, the corrugated segment of the strap members comprises at least four ridges. In further embodiments, the corrugated segment comprise more than four ridges.

In some embodiments, the suspension is of unitary construction, for example with the central portion and the strap members of the suspension being integrally formed.

The suspension can also comprise a plurality of strap members. In one embodiment, the plurality of strap members comprises four strap members, and suspension comprises first and second straps, each of the first and second suspension straps comprising two of the plurality of strap members, the first and second suspension straps each having an uncorrugated central section, the uncorrugated central sections of the first and second suspension straps overlapping with one another to form the central portion. The uncorrugated central section of the first suspension strap may be recessed such that when it overlaps with the uncorrugated central section of the second suspension strap, the resulting formed central portion is substantially flat and level with the rest of the suspension straps. The suspension may comprise a plurality of separate straps, wherein each of the plurality of separate straps comprises two of the plurality of strap members, the straps each having an uncorrugated central section, the uncorrugated central sections of the straps overlapping with one another to form the central portion.

In another embodiment, the present disclosure provides a hard hat for receiving and protecting a wearer's head, comprising a rigid outer shell and a suspension. In such an embodiment, the suspension comprises a central portion and a plurality of resilient impact absorbing strap members depending from the central portion. At least some of the plurality of strap members comprise a corrugated segment and terminating in an uncorrugated attachment end that is configured for attachment to an inner surface of the rigid outer shell. The additional aspects described above, and in further detail later herein, in relation to optional features of the strap members and the central portion are equally applicable to this embodiment including the hard hat's rigid outer shell.

Other aspects and features of the present disclosure will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments in conjunction with the accompanying figures.

In describing the suspension herein, a skilled person would readily understand that certain terminology has been adopted to describe the suspension prior to installation in the hard hat (e.g. as depicted in FIGS. 1 to 9 in a generally flat configuration) and that some terms used herein refer to the shape or configuration of the suspension and its parts refer to the substantially flat configuration. A skilled person would readily understand that installation of the suspension would result in curving of the straps, for instance, such that what is described as “flat” or “substantially flat” would be a curved flat surface once installed in an outer shell of a hard hat.

A “corrugated” portion or segment of a strap member means that at least a portion of the strap member is wavy, serpentine, or sinusoidal. The purpose of the corrugated segment is to impart resilience and absorb horizontal or vertical impact, thereby cushioning and protecting a wearer's head.

According to an example embodiment of the present disclosure, the flat nylon straps of known hard hat suspensions are replaced with injection moulded plastic suspension straps, or strap members. The injection moulded plastic straps of an example embodiment can be formed integral with the locking clips that clip into apertures in the hat shell, to which a circumferential head strap can be secured. The plastic suspension straps of an example embodiment include a serpentine shape or corrugated pattern, making them strong enough for the desired absorption, without breaking. During impact the corrugations straighten out, absorbing the energy to allow the hat to pass safety standards testing.

The straightening out of the corrugated injection moulded strap of example embodiments of the present disclosure is a different approach than absorption by the stretching of a nylon strap, which is used in known approaches. A thin uncorrugated strap, as used in known approaches, will break under pressure; a thick uncorrugated strap makes the wearer's head absorb the energy, rather than the straps. Impact absorbing corrugated strap members according to example embodiments of the present disclosure include a corrugated segment and an uncorrugated attachment end. While corrugations or other locking mechanisms are known for strap adjustment or securing the attachment end of a strap to a hard hat shell, only flat uncorrugated straps have been used for the impact absorbing portion of the strap.

The suspension is also a large contributor to the overall production expense of the hard hat, in terms of material and labour. At least some embodiments of the present disclosure provide a suspension that has a decreased cost of production without decreased performance.

FIG. 1 depicts a hard hat suspension 100 of an example embodiment of the present disclosure. The suspension comprises a central portion 110 for resting on the wearer's head, and a plurality of resilient impact-absorbing corrugated strap members 122, 124, 126, 128 depending therefrom. In an embodiment, at least one strap member comprises a corrugated segment. For example, at least some of a plurality of strap members comprise a corrugated segment. In the example embodiment of FIG. 1, each strap member 122, 124, 126, 128 comprises a corrugated segment 132, 134, 136, 138 and terminates in an uncorrugated attachment end 142, 144, 146, 148.

In the example embodiment depicted in FIG. 1, the four strap members 122, 124, 126, 128 are placed in an X-shaped configuration, or a substantially X-shaped configuration. The strap members are positioned to define a first pair of opposing obtuse angles 162 within the X-shape, and a second pair of opposing acute angles 164 within the X-shape. In another embodiment, the plurality of strap members are distributed substantially equidistantly about the perimeter of the central portion of the suspension.

In the example embodiment of FIG. 1, the four strap members 122, 124, 126, 128 comprise two pairs of diagonally opposing strap members 122, 126 and 124, 128, with each diagonally opposing strap member being substantially parallel to the other strap member in its pair. For example, 122 and 126 are substantially parallel, and 124 and 128 are substantially parallel.

In the example embodiment of FIG. 1, the uncorrugated attachment end 142, 144, 146, 148 of each strap member is angled at points 140 with respect to the corrugated segment of the strap member 132, 134, 136, 138. This configuration permits the suspension to be installed in a rigid shell of a hard hat with less stress, allowing impact absorption to be more uniformly distributed across each strap member.

In the example embodiment of FIG. 1, each strap member has an attachment segment 152, 154, 156, 158 defining attachment holes (exemplified by 150) which may be used for engaging a conventional hard hat headband, such as an adjustable headband (not shown). The suspension 100 may be of unitary construction, as depicted in FIG. 1. It may be integrally formed, such as using injection molding.

FIG. 2 depicts a suspension 200 in accordance with another embodiment of the present disclosure in which the central portion is elongated and the strap members are not angled. The suspension 200 comprises dependent strap members 222, 224, 226, 228 each having a corrugated segment 232, 234, 236, 238. FIG. 2 also illustrates attachment ends 242, 244, 246, 248, and attachment segments 252, 254, 256, 258 defining attachment holes, as exemplified by 250.

In the example embodiment of FIG. 2, the strap members 222, 224, 226, 228 are in an X-shaped configuration. The central portion 210 in FIG. 2 is elongated in one dimension to position the strap members for attachment to the rigid outer shell with minimal stress. This permits impact absorption to be more uniformly distributed across each strap. In this embodiment, there is no angling of strap members 222, 224, 226, 228, between the attachments ends 242, 244, 246, 248 and the corrugated segments 232, 234, 236, 238, with each strap member being substantially linear along its length, with optional tapering as shown.

In the example embodiment of FIG. 2, diagonally opposing strap members are offset from one another. For instance, although they are parallel, strap member 222 is offset from its diagonally opposed strap member 226, while strap member 224 is offset from its diagonally opposed strap member 228.

FIG. 3 depicts a suspension 300 in accordance with another embodiment of the present disclosure in which a central aperture is provided in the central portion. The suspension 300 comprises dependent strap members 322, 324, 326, 328 each having a corrugated segment 332, 334, 336, 338. FIG. 3 also illustrates attachment ends 342, 344, 346, 348, and attachment segments 352, 354, 356, 358 defining attachment holes, as exemplified by 350. In the example embodiment of FIG. 3, the strap members 322, 324, 326, 328 are in an X-shaped configuration.

In this embodiment, the central portion 310 in FIG. 3 is elongated in one dimension to position the strap members for attachment to the rigid outer shell with minimal stress. This permits impact absorption to be more uniformly distributed across each strap. In the example embodiment of FIG. 3, the central portion 310 defines a central aperture 311 for weakening the central portion to improve shock absorption. The central aperture 311 in the example embodiment of FIG. 3 is ovoid, and the central aperture 311 has relative dimensions that are similar to the relative dimensions of the central portion 310 itself. In another embodiment, the central portion and the central aperture defined thereby are of another shape. Examples of other shapes for the central portion in other embodiments include square, rectangular, triangular, diamond, and any other suitable shape. In another embodiment, the central aperture has relative dimensions that are dissimilar to the dimensions of the central portion.

In the example embodiment of FIG. 3, as in FIG. 2, there is no angling of strap members 322, 324, 326, 328, between the attachments ends 342, 344, 346, 348 and the corrugated segments 332, 334, 336, 338, with each strap member being substantially linear along its length.

In the example embodiment of FIG. 3, also as in FIG. 2, diagonally opposing strap members are offset from one another. For instance, although they are parallel, strap member 322 is offset from its diagonally opposed strap member 326, while strap member 324 is offset from its diagonally opposed strap member 328.

FIGS. 4 to 9 illustrate elements of other embodiments in which the suspension comprises a plurality of separate suspension straps each having an uncorrugated central section. One of these separate suspension straps is illustrated in each of FIGS. 4 to 9, with each suspension strap effectively combining two of the previously described strap members. These example embodiments illustrate and describe a suspension strap that is used in a suspension having two cooperating suspension straps. Other embodiments can include more than two cooperating suspension straps. The uncorrugated central sections of the suspension straps overlap with one another to form the central portion when the suspension is assembled. In one embodiment with two separate suspension straps, the uncorrugated central section of a first suspension strap is recessed such that when it overlaps with a central section of a second suspension strap, the resulting formed central portion is substantially flat and level with the rest of the straps.

FIGS. 4 and 5 depict a suspension strap 420 in accordance with an embodiment of the present disclosure. The suspension strap 420 comprises corrugated segments 432, 436 and attachment ends 442, 446 configured to be releasably secured in a hard hat shell. Attachment segments 452, 456 are also provided defining attachment holes, as exemplified by 450, for engaging a hard hat headband. In an example embodiment, the suspension strap 420 is a functional equivalent of two diagonally opposite strap members described in FIGS. 1 to 3, with the diagonally opposite strap members joined together and forming a part of the central portion of the suspension.

In the example embodiment depicted in FIGS. 4 and 5, two corrugated segments 432, 436 are separated by a non-corrugated segment 410. In this embodiment, each corrugated segment 432, 436 comprises four ridges exemplified by 430, the ridges projecting towards the inner surface of the rigid outer shell (not shown). The ridges 430 are separated by flat spacer portions exemplified by 431 configured to comfortably abut the wearer's head. In other embodiments, the corrugated segments comprise a different number of ridges and flat spacer portions.

FIGS. 6 and 7 depict a suspension strap 520 in accordance with another embodiment of the present disclosure. The suspension strap 520 comprises corrugated segments 532, 536 comprising two rows of corrugations, each pair of rows defining an aperture exemplified by 533 therebetween. The aperture 533 serves to weaken the adjacent corrugated rows and improves overall shock absorption.

Attachment ends 542, 546 are configured to be releasably secured in a hard hat shell. Attachment segments 552, 556 are also provided defining attachment holes, as exemplified by 550, for engaging a hard hat headband. In an example embodiment, the suspension strap 520 is a functional equivalent of two diagonally opposite strap members described in FIGS. 1 to 3, with the diagonally opposite strap members joined together and forming a part of the central portion of the suspension.

In the example embodiment depicted in FIGS. 6 and 7, two corrugated segments 532, 536 are separated by a non-corrugated segment 510. In this embodiment, each corrugated segment 532, 536 comprises three ridges exemplified by 530, the ridges projecting towards the inner surface of the rigid outer shell (not shown). The ridges 530 are separated by flat spacer portions exemplified by 531 configured to comfortably abut the wearer's head. In other embodiments, the corrugated segments comprise a different number of ridges and flat spacer portions. FIG. 7 depicts and example embodiment in which aperture 533 includes rounded ends 535 which extend beyond the corresponding corrugated segment 532 in which the aperture is defined.

FIGS. 8 and 9 depict a suspension strap 620 in accordance with another embodiment of the present disclosure, in which four ridges are provided in the two rows of corrugations. The suspension strap 620 comprises corrugated segments 632, 636 and attachment ends 642, 646 configured to be releasably secured in a hard hat shell. Attachment segments 652, 656 are also provided and define attachment holes, as exemplified by 650, for engaging a hard hat headband. In an example embodiment, the suspension strap 620 is a functional equivalent of two diagonally opposite strap members described in FIGS. 1 to 3, with the diagonally opposite strap members joined together and forming a part of the central portion of the suspension.

In the example embodiment depicted in FIGS. 8 and 9, two corrugated segments 632, 636 are separated by a non-corrugated segment 610. In this embodiment, each corrugated segment 632, 636 comprises four ridges exemplified by 630, the ridges projecting towards the inner surface of the rigid outer shell (not shown). The ridges 630 are separated by flat spacer portions exemplified by 631 configured to comfortably abut the wearer's head.

In the example embodiment depicted in FIGS. 8 and 9, the corrugated segments 632, 636 comprise two rows of corrugations, each pair of rows defines an aperture exemplified by 633 therebetween. The aperture 633 serves to weaken the adjacent corrugated rows and improves overall shock absorption. FIG. 9 depicts and example embodiment in which aperture 633 includes rounded ends 635 which extend beyond the corresponding corrugated segment 632 in which the aperture is defined.

A skilled person would appreciate that features depicted for the “separately formed strap” embodiments of FIGS. 4 to 9, such as specific number of corrugations, rows of corrugations defining an aperture therebetween, design parameters, etc., could also be employed in “unitary construction” embodiments depicted in FIGS. 1 to 3. Conversely, a skilled person would recognize that features pertaining to the configuration of dependent strap members in the “unitary construction” embodiments (angling, etc.) could be applied to the “separately formed strap” embodiments, since each separately formed strap has two opposite sides (flanking the central non-corrugated segment) which could effectively be taken as the equivalent of dependent strap members in the “unitary construction” embodiments.

Generally, features of the corrugations may be adjusted to provide different or improved shock absorption characteristics. For example, in some embodiments, more corrugations may be used.

In some embodiments, no headband would be required, and the above-described attachment segments could therefore be omitted from such embodiments.

Hard hats and suspensions according to some embodiments are capable of absorbing horizontal and vertical impact force. In some embodiments, the hard hat meets safety standards, such as those set by the Canadian Standards Association (CSA), and which would be known to a skilled person.

Individual non-limiting advantages of some (but not necessarily all) embodiments include that they may be easier to manufacture, may be cheaper to manufacture, may reduce labour costs, may improve safety, may be more comfortable to the wearer, and/or may be cooler (e.g. better ventilated).

In the preceding description, for purposes of explanation, numerous details are set forth in order to provide a thorough understanding of the embodiments. However, it will be apparent to one skilled in the art that these specific details are not required. The above-described embodiments are intended to be examples only. Alterations, modifications and variations can be effected to the particular embodiments by those of skill in the art without departing from the scope, which is defined solely by the claims appended hereto. 

What is claimed is:
 1. A hard hat suspension for use in a hard hat for protecting a wearer's head, comprising: a central portion for resting on the wearer's head; and a plurality of resilient impact absorbing corrugated strap members depending from the central portion, at least some of the plurality of strap members comprising a corrugated segment and terminating in an uncorrugated attachment end that is configured for attachment to the hard hat.
 2. The hard hat suspension of claim 1, wherein each of the plurality of strap members comprises the corrugated segment and terminates in the uncorrugated attachment end.
 3. The hard hat suspension of claim 1, wherein the plurality of strap members are distributed substantially equidistantly about the perimeter of the central portion of the suspension.
 4. The hard hat suspension of claim 1, wherein the plurality of strap members comprises four strap members positioned in a substantially X-shaped configuration.
 5. The hard hat suspension of claim 4, wherein the strap members are positioned to define a first pair of opposing obtuse angles within the X-shape, and a second pair of opposing acute angles within the X-shape.
 6. The hard hat suspension of claim 4, wherein the four strap members comprise two pairs of diagonally opposing strap members, each diagonally opposing strap member being substantially parallel to the other strap member in its pair.
 7. The hard hat suspension of claim 4, wherein the central portion is elongated in one dimension to position the strap members for attachment to the rigid outer shell with minimal stress.
 8. The hard hat suspension of claim 4, wherein the uncorrugated attachment end of each strap member is angled with respect to the corrugated segment of the strap member.
 9. The hard hat suspension of claim 4, wherein the diagonally opposing strap members are offset from one another.
 10. The hard hat suspension of claim 1, wherein the corrugated segment of at least one of the strap members comprises two rows of corrugations.
 11. The hard hat suspension of claim 10, wherein the two rows of corrugations define an aperture therebetween.
 12. The hard hat suspension of claim 1, wherein the corrugated segment of each of the strap members comprises ridges which project towards the inner surface of the rigid outer shell.
 13. The hard hat suspension of claim 12, wherein the ridges are separated by flat spacer portions configured to comfortably abut the wearer's head.
 14. The hard hat suspension of claim 1, wherein the central portion defines a central aperture for weakening the central portion and improving shock absorption.
 15. The hard hat suspension of claim 14, wherein the central aperture is ovoid.
 16. The hard hat suspension of claim 1, wherein the corrugated segment of each strap member comprises at least three ridges.
 17. The hard hat suspension of claim 1, wherein the corrugated segment of each strap member comprises at least four ridges.
 18. The hard hat suspension of claim 1, wherein the suspension is of unitary construction.
 19. The hard hat suspension of claim 18, wherein the central portion and the strap members of the suspension are integrally formed.
 20. The hard hat suspension of claim 1, wherein the plurality of strap members comprises four strap members, and suspension comprises first and second straps, each of the first and second suspension straps comprising two of the plurality of strap members, the first and second suspension straps each having an uncorrugated central section, the uncorrugated central sections of the first and second suspension straps overlapping with one another to form the central portion.
 21. The hard hat suspension of claim 20, wherein the uncorrugated central section of the first suspension strap is recessed such that when it overlaps with the uncorrugated central section of the second suspension strap, the resulting formed central portion is substantially flat and level with the rest of the suspension straps.
 22. The hard hat suspension of claim 1, wherein the suspension comprises a plurality of separate straps, and wherein each of the plurality of separate straps comprises two of the plurality of strap members, the straps each having an uncorrugated central section, the uncorrugated central sections of the straps overlapping with one another to form the central portion.
 23. A hard hat for receiving and protecting a wearer's head comprising: a rigid outer shell; and a hard hat suspension including a central portion for resting on the wearer's head, and a plurality of resilient impact absorbing corrugated strap members depending from the central portion, at least some of the plurality of strap members comprising a corrugated segment and terminating in an uncorrugated attachment end that is configured for attachment to the hard hat.
 24. A hard hat for receiving and protecting a wearer's head comprising: a rigid outer shell; and a suspension comprising a central portion for resting on the wearer's head, and a plurality of resilient impact absorbing strap members depending from the central portion, at least some of the plurality of strap members comprising a corrugated segment and terminating in an uncorrugated attachment end that is configured for attachment to an inner surface of the rigid outer shell. 